Process of manufacturing a core metal insert

ABSTRACT

A core metal insert for use in a sealing assembly is disclosed. The core metal insert is manufactured by a process which includes the step of cutting a plurality of left lateral outermost inboard slits and a plurality of right lateral outermost inboard slits in a metal blank so as to create a slitted metal blank. The process of manufacturing the core metal insert further includes the step of coining the slitted metal blank so that the core metal insert is manufactured with (i) a plurality of left lateral outermost inboard gaps defined therein, (ii) a plurality of right lateral outermost inboard gaps defined therein, (iii) a left lateral coin-formed bridge which is positioned within each left lateral outermost inboard gap of the plurality of left lateral outermost inboard gaps and which divides each left lateral outermost inboard gap into a first left lateral outermost inboard subgap and a second left lateral outermost inboard subgap, each of the first left lateral outermost inboard subgap and the second left lateral outermost inboard subgap extends through the core metal insert, and (iv) a right lateral coin-formed bridge which is positioned within each right lateral outermost inboard gap of the plurality of right lateral outermost inboard gaps and which divides each right lateral outermost inboard gap into a first right lateral outermost inboard subgap and a second right lateral outermost inboard subgap, each of the first right lateral outermost inboard subgap and the second right lateral outermost inboard subgap extends through the core metal insert.

[0001] This application is a continuation of co-pending application Ser.No. 09/732,284, filed on Dec. 7, 2000 which in turn is a continuation ofco-pending application Ser. No. 09/164,290, filed on Oct. 1, 1998.

BACKGROUND OF THE INVENTION

[0002] The present invention relates generally to a core metal insertwhich is used in a sealing assembly of an automobile or the like. Thepresent invention also relates generally to a method of manufacturingsuch a core metal insert.

[0003] Sealing assemblies are commonly used in automobiles in order toseal areas adjacent to the doors, windows, and trunk covers. The sealingassemblies typically include a metallic inner member and an elastomericouter member. The metallic inner member, commonly referred to as a “coremetal insert,” provides structural integrity to the sealing assembly,while the elastomeric outer member provides the sealing assembly withits ability to seal against objects such as doors, windows or truckcovers.

[0004] One challenge when designing a sealing assembly is to obtain acore metal insert that has a configuration which facilitates long-termattachment of the elastomeric material to the core metal insert wherebydurability of the sealing assembly is achieved. Note that the sealingassembly is subjected to repeated contact with a movable object such asan automobile door, window or truck cover. Thus, durability of thesealing assembly is important goal.

[0005] It would also be desirable to obtain long-term attachment of theelastomeric material to the core metal insert without the need tochemically treat the core metal insert prior to attaching theelastomeric material to the core metal insert. Eliminating amanufacturing step in the process of making the sealing assembly wouldreduce the cost of the sealing assembly.

[0006] Another challenge when designing a sealing assembly is to obtaina core metal insert which is relatively light weight yet still providesstructural integrity to the sealing assembly. Reducing weight ofcomponents of an automobile such as a sealing assembly reduces fuelconsumption of the automobile.

[0007] Yet another challenge when designing a sealing assembly is toobtain a core metal insert that has a configuration which facilitatesbending of the core metal insert during manufacture of the sealingassembly. In particular, obtaining a core metal insert which isrelatively easy to bend during manufacture of the sealing assemblyreduces manufacturing costs since less exotic bending equipment may beused to bend the core metal insert to a desired shape prior toattachment of the elastomeric material to the core metal insert.

SUMMARY OF THE INVENTION

[0008] According to one embodiment of the present invention, there isprovided a core metal insert for use in a sealing assembly. The coremetal insert is manufactured by a process including the step of cuttinga plurality of inboard slits in a metal blank so as to create a slittedmetal blank. The process of manufacturing the core metal insert furtherincludes the step of coining the slitted metal blank so that the coremetal insert is manufactured with (i) a plurality of inboard gapsdefined therein, and (ii) a coin-formed bridge which is positionedwithin each inboard gap of the plurality of inboard gaps and whichdivides each inboard gap of the plurality of inboard gaps into a firstinboard subgap and a second inboard subgap, each of the first inboardsubgap and the second inboard subgap extends through the core metalinsert.

[0009] According to another embodiment of the present invention, thereis provided a method of manufacturing a core metal insert which isadapted to be used in a sealing assembly. The method includes the stepsof (i) cutting a plurality of inboard slits in a metal blank so as tocreate a slitted metal blank, and (ii) coining a swath in the slittedmetal blank so that the slitted metal blank is expanded to create thecore metal insert with a plurality of inboard gaps defined therein. Eachinboard gap of the plurality of inboard gaps extends from a left lateralinboard gap end to a right lateral inboard gap end. The swath isoriented relative to the plurality of inboard gaps such that, when thecore metal insert is viewed in a plan view, (i) the swath forms anintersection with each inboard gap of the plurality of inboard gaps, and(ii) the swath is spaced apart from each of the left lateral inboard gapend and the right lateral inboard gap end.

[0010] Yet according to another embodiment of the present invention,there is provided a core metal insert for use in a sealing assembly, thecore metal insert being manufactured by a process including the steps of(i) cutting a plurality of inboard slits in a metal blank so as tocreate a slitted metal blank, and (ii) coining a swath in the slittedmetal blank so that the slitted metal blank is expanded to create thecore metal insert with a plurality of inboard gaps defined therein. Thecoining step includes the step of displacing a quantity of metal of theslitted metal blank so as to create a coin-formed bridge with thequantity of metal which (A) is positioned within each of the pluralityof inboard gaps, and (B) divides each inboard gap of the plurality ofinboard gaps into a first inboard subgap and a second inboard subgap.Each of the first inboard subgap and the second inboard subgap extendsthrough the core metal insert.

[0011] According to another embodiment of the present invention, thereis provided a core metal insert for use in a sealing assembly, the coremetal insert being manufactured by a process including the step ofcutting a plurality of left lateral outermost inboard slits and aplurality of right lateral outermost inboard slits in a metal blank soas to create a slitted metal blank. The process of manufacturing thecore metal insert further includes the step of coining the slitted metalblank so that the core metal insert is manufactured with (i) a pluralityof left lateral outermost inboard gaps defined therein, (ii) a pluralityof right lateral outermost inboard gaps defined therein, (iii) a leftlateral coin-formed bridge which is positioned within each left lateraloutermost inboard gap of the plurality of left lateral outermost inboardgaps and which divides each left lateral outermost inboard gap into afirst left lateral outermost inboard subgap and a second left lateraloutermost inboard subgap, each of the first left lateral outermostinboard subgap and the second left lateral outermost inboard subgapextends through the core metal insert, and (iv) a right lateralcoin-formed bridge which is positioned within each right lateraloutermost inboard gap of the plurality of right lateral outermostinboard gaps and which divides each right lateral outermost inboard gapinto a first right lateral outermost inboard subgap and a second rightlateral outermost inboard subgap, each of the first right lateraloutermost inboard subgap and the second right lateral outermost inboardsubgap extends through the core metal insert.

[0012] One object of the present invention is to provide a new anduseful core metal insert.

[0013] Another object of the present invention is to provide an improvedcore metal insert.

[0014] Still another object of the present invention is to provide a newand useful method of manufacturing a core metal insert.

[0015] Yet another object of the present invention is to provide animproved method of manufacturing a core metal insert.

[0016] Still another object of the present invention is to provide acore metal insert that has a configuration which facilitates long-termattachment of the elastomeric material to the core metal insert wherebydurability of the sealing assembly is achieved.

[0017] Another object of the present invention is to provide a coremetal insert which is configured so that it does not need to bechemically treated prior to attaching the elastomeric material to thecore metal insert and yet still enables long-term attachment of theelastomeric material to the core metal insert.

[0018] Yet another object of the present invention is to provide a coremetal insert which is relatively light weight yet still providesstructural integrity to a sealing assembly.

[0019] Still another object of the present invention is to provide acore metal insert that has a configuration which facilitates bending ofthe core metal insert during manufacture of the sealing assembly.

[0020] Other objects and benefits of the present invention can bediscerned from the following description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021]FIG. 1 is a perspective view of an automobile which incorporatesthe features of the present invention therein;

[0022]FIG. 2 is a cross sectional view of a sealing assembly of theautomobile of FIG. 1 which is taken along the line 2-2 of FIG. 1 asviewed in the direction of the arrows, with FIG. 2 also showing a doorframe and a window of the automobile of FIG. 1 in phantom for clarity ofdescription;

[0023]FIG. 3 is a plan view (or top elevational) of a metal segmentwhich is in-process of being manufactured in accordance with a method ofthe present invention, with (i) the portion A comprising a completedsegment of the core metal insert which is used in the sealing assemblyof FIG. 2, and (ii) the portion B comprising an in-process segment of aslitted metal blank;

[0024]FIG. 4 is a cross sectional view of the core metal insert of FIG.3 which is taken along the line 4-4 of FIG. 3 as viewed in the directionof the arrows;

[0025]FIG. 5 is a schematic view of a first set of rollers whichfunction to cut slits into a blank metal workpiece and a second set ofrollers which function to coin the slitted blank metal workpiece so asto manufacture the core metal insert of FIG. 3 in accordance with amethod of the present invention;

[0026]FIG. 6 is a cross sectional view which is taken along the line 6-6of FIG. 5 as viewed in the direction of the arrows;

[0027]FIG. 7 is an enlarged view of a portion of FIG. 3 which isencircled and indicated as FIG. 7; and

[0028]FIG. 8 is an enlarged view of a portion of FIG. 7 showing aleading leg portion and a respective trailing leg portion whichcollectively define an inboard gap which has been divided by acoin-formed bridge into a first inboard subgap and a second inboardsubgap.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] While the invention is susceptible to various modifications andalternative forms, a specific embodiment and method thereof has beenshown by way of example in the drawings and will herein be described indetail. It should be understood, however, that there is no intent tolimit the invention to the particular form disclosed, but on thecontrary, the intention is to cover all modifications, equivalents, andalternatives falling within the spirit and scope of the invention asdefined by the appended claims.

[0030] Referring now to the drawings, FIG. 1 shows an automobile 10which incorporates features of the present invention therein. Theautomobile 10 includes a driver door 12 having a window 14 which is ableto be moved between a raised position and a lowered position within thedoor 12. Note that the window 14 is shown in the raised position in FIG.1.

[0031] The door 12 includes a sealing assembly 16 as shown in FIG. 2.During manufacture of the automobile 10, the sealing assembly 16 issecured to a frame 18 of the door 12. The sealing assembly 16 includes achannel 20 which receives an upper end of the window 14 therein when thewindow is located in its raised position as shown in FIG. 2.

[0032] The sealing assembly 16 includes a core metal insert 22 and anelastomeric material 24 which are secured together. The core metalinsert 22 is preferably made from steel. Moreover, types of elastomericmaterials which may be used in the present invention is rubber orsynthetic resin. Types of rubbers which may be appropriate for use withthe present invention is sponge rubber, EDPM rubber, or polyvinylchloride rubber.

[0033]FIG. 3 shows a metal segment 21 which is in-process of beingmanufactured into the core metal insert 22. In particular, a portion Aof the metal segment 21 comprises a completed segment of the core metalinsert 22, while a portion B of the metal segment 21 comprises anin-process segment of a slitted metal blank 23. It should be appreciatedthat the slitted metal blank 23 is a continuous strip of metal which maybe rolled and have an extremely long length (e.g. 20,000 feet).

[0034] The slitted metal blank 23 (see portion B of FIG. 3) includes aplurality of inboard slits 26 and a plurality of outboard slits 27defined therein. Note that the slits 26, 27 are created in the slittedmetal blank 23 as a result of a cutting or slitting operation. The slits26, 27 remain in the slitted metal blank 23 until the slitted metalblank is subjected to a coining operation. The plurality of slits 26, 27are substantially linear in shape and are oriented in a width-wisedirection relative to a processing direction 28 (see also FIG. 5) of thecore metal insert 22. The inboard slits 26 are spaced inward from eachof the lateral ends 25 of the metal segment 21, while the outboard slits27 are juxtaposed to at least one of the lateral ends 25 of the metalsegment 21. Each of the inboard lateral slits extends continuously froma left lateral slit end 26 a to a right lateral slit end 26 b as show inFIG. 3.

[0035] The core metal insert 22 (see portion A of FIG. 3) has aplurality of inboard gaps 30 defined therein. The outermost inboard gaps30 are indicated with the designation “LL” or “RL” to signify if it is aleft lateral outermost inboard gap 30LL or a right lateral outermostinboard gap 30RL. In order to provide meaning to the term “outermost” asit is used herein, it should be appreciated that there does no exist anyinboard gaps 30 to the left in a width-wise direction of a left lateraloutermost inboard gap 30LL. Moreover, it should be appreciated thatthere does no exist any inboard gaps 30 to the right in a width-wisedirection of a right lateral outermost inboard gap 30RL. Thedesignations “LL” and “RL” are used with other elements of the coremetal insert 22 and such designations have a similar meaning to thatdescribed above with respect to the left lateral outermost inboard gap30LL and the right lateral outermost inboard gap 30RL.

[0036] The core metal insert 22 further includes a plurality of leadingleg portions 34 and a plurality of trailing leg portions 36. Eachinboard gap 30 is defined collectively by one of the leading legportions 34 and a respective one of the trailing leg portions 36. Inparticular, a respective leg portion pair 34, 36 collectively define anentire outer boundary of each inboard gap 30 (see e.g. FIG. 8). As aresult, each of the inboard gaps 30 is spaced inward from each of thelateral ends 25. The plurality of inboard gaps 30 form a number ofcolumns C1 as shown in FIG. 3. Each of the columns C1 of the inboardgaps 30 are oriented length-wise relative to the processing direction28.

[0037] It should be noted that the sectional views shown in FIGS. 2 and6 are taken at a location of the core metal insert 22 where no inboardgaps 30 or outboard gaps 31 are present. This is why each of theabove-identified cross sectional views shows a continuous metal crosssection along the entire width of the core metal insert 22. However,FIG. 4 does show an inboard gap 30 and an outboard gap 31 in crosssection at the right lateral side of the drawing.

[0038] The core metal insert 22 (see portion A of FIG. 3) further has aplurality of outboard gaps 31. The outboard gaps are non-bounded by themetal of the core metal insert 22 and are juxtaposed to at least one ofthe lateral ends 25 of the metal segment 21 as shown in FIG. 3. Morespecifically, each of the outboard gaps 31 are open at a lateral end 25as indicated at arrow 38 in FIG. 7. The plurality of outboard gaps 31form a number of columns C2 as shown in FIG. 3. Each of the columns C2of the outboard gaps 31 are also oriented length-wise relative to theprocessing direction 28.

[0039] The core metal insert 22 further includes a plurality of linearcoin swaths 40. Each coin swath 40 is created in the slitted metal blank23 as a result of the slitted metal blank being subjected to a coiningprocess. As the slitted metal blank is coined to form the linear coinswaths 40, a quantity of metal is displaced so as to create a number ofcoin-formed bridges 42 each which is positioned in each inboard gap ofcertain columns of inboard gaps C1 as shown in FIG. 3. Each of the coinswaths 40 are linear in shape and are oriented in a length-wisedirection relative to the processing direction 28. Note that the linearcoin swaths 40 are perpendicularly oriented relative to the linear slits26 of the slitted metal blank 23.

[0040] As shown in FIGS. 7 and 8, each coin-formed bridge 42 includes aleading bridge portion 44 which extends into a respective inboard gap 30from a respective leading leg portion 34. Similarly, each coin-formedbridge 42 further includes a trailing bridge portion 46 which extendsinto a respective inboard gap 30 from a respective trailing leg portion36. The leading bridge portion 44 contacts the trailing bridge portion46 so that the coin-formed bridge 42 continuously extends from theleading leg portion 34 to the trailing leg portion as shown in FIGS. 7and 8.

[0041] Each coin-formed bridge 42 divides a respective inboard gap 30into a first inboard subgap 48 and a second inboard subgap 50 (see FIG.8). Each subgap 48, 50 extends through the core metal insert 22 in amanner similar to the described with respect to gaps 30 and 31. This isan important aspect of the present invention since during manufacture ofthe sealing assembly 16, melted elastomeric material 24 flows throughand becomes permanently located within each of the numerous subgaps 48and 50, and thereafter adheres or bonds to itself so as to entrap thecore metal insert 22 securely within the elastomeric material 24. Thepresence of a relatively large number of the subgaps 48, 50 definedwithin the core metal insert 22 functions to enhance the entrapment ofthe core metal insert 22 within the elastomeric material 24. Thisincreases the durability of the sealing assembly 16. This increaseddurability is achieved even without chemically treating the core metalinsert 22 prior to attaching or adhering the elastomeric material 24 tothe core metal insert.

[0042] It should be noted that, when the core metal insert 22 is viewedin a plan view such as FIG. 3, the linear coin swaths 40 each forms ordefines an intersection 52 with a respective inboard gap 30 as shown inFIGS. 7 and 8. The locations of the coin-formed bridges 42 defines thelocations of the intersections 52.

[0043] Each of the inboard gaps 30 extends from a left lateral inboardgap end 17 to a right lateral inboard gap end 19 as shown in FIG. 8.Each of the coin swaths 40 is defined in the core metal insert 22 suchthat each swath 40 is spaced apart from each respective left lateralinboard gap end 17 and each respective right lateral inboard gap end 19as shown in FIG. 8 (see also FIG. 7).

[0044] Turning now to FIGS. 5 and 6, there is shown a first set ofrollers 54 and a second set of rollers 56. Each of the first set ofrollers 54 and the second set of rollers 56 are driven by a motor 58.The first set of rollers 54 operate to perform a cutting or slittingprocess whereby slits 26 are cut into a blank metal plate. The first setof rollers 54 cuts or slits a metal blank 60 which is received into anip 62 defined between the rollers 54. The output of the first set ofrollers 54 is the slitted metal blank 23.

[0045] The second set of rollers 56 operate to perform a coining processon the slitted metal blank 23 whereby the slitted metal blank 23 isexpanded to create the core metal insert 22 with the plurality ofinboard gaps 30 and the plurality of outboard gaps 31 defined therein.The second set of rollers 56 functions to coin the slitted metal blank23 which is received into a nip 64 defined between the rollers 56. Thesecond set of rollers 56 also function to form coin swaths 40 in theslitted metal blank 23 thereby displacing a quantity of metal intocertain of the plurality of inboard gaps 30 so as to create theplurality of coin-formed bridges 42 thereby forming the subgaps 48 and50. The output of the second set of rollers 56 is the core metal insert22.

[0046] The second set of rollers 56 include an upper roller 66 and alower roller 67. The upper roller 66 includes a plurality of swath diemembers 68 which cooperate with the lower roller 67 to form the swaths40 into the core metal insert 22.

[0047] It should be noted that, as shown in FIG. 3, the core metalinsert 22 advantageously has a left lateral coin swath 40LL coinedtherein such that a number of left lateral coin-formed bridges 42LL arerespectively positioned in each of the plurality left lateral outermostinboard gaps 30LL. Additionally, the core metal insert 22 advantageouslyhas a right lateral coin swath 40RL coined therein such that a number ofright lateral coin-formed bridges 42RL are respectively positioned ineach of the plurality right lateral outermost inboard gaps 30RL. Coiningthe core metal insert 22 in such a manner provides for more evenexpansion of the core metal insert 22 in the processing direction 28.

[0048] While the invention has been described in detail in the drawingsand foregoing description, the same is to be considered as illustrativeand not restrictive in character, it being understood that only thepreferred embodiments and methods have been shown and described and thatall changes and modifications that come within the spirit of theinvention are desired to be protected.

What is claimed is:
 1. A process of manufacturing a core metal insert,including the steps of: forming in a metal blank at least one inboardslit which extends continuously from a left lateral slit end to a rightlateral slit end; and expanding said metal blank to create an inboardgap therein, said expanding step including the step of displacing aquantity of metal of said metal blank so as to create a bridge with saidquantity of metal which (i) is positioned within said inboard gap, and(ii) divides said inboard gap into a first inboard subgap and a secondinboard subgap, wherein said bridge is spaced apart from both said leftlateral slit end and said right lateral slit end.
 2. The process ofclaim 1, wherein each of said first inboard subgap and said secondinboard subgap extends through said core metal insert.
 3. The process ofclaim 1, wherein said expanding step further includes the step offorming a coin swath in said metal blank which traverses said at leastone inboard slit so that said metal blank is expanded thereby creatingsaid inboard gap.
 4. The process of claim 3, wherein said coin swathwhich is formed in said metal blank is a linear coin swath.
 5. Theprocess of claim 1, wherein said inboard gap is defined by a leading legportion and a trailing leg portion of said core metal insert whichcollectively define an entire outer boundary of said inboard gap.
 6. Theprocess of claim 5, wherein said bridge includes (i) a leading bridgeportion which extends into said inboard gap from said leading legportion, and (ii) a trailing bridge portion which extends into saidinboard gap from said trailing leg portion.
 7. The process of claim 6,wherein said leading bridge portion contacts said trailing bridgeportion so that said bridge continuously extends from said leading legportion to said trailing leg portion.
 8. The process of claim 1,wherein: said at least one inboard slit is oriented in a firstdirection, said expanding step includes the step of forming a linearcoin swath in said metal blank, said linear coin swath is oriented in asecond direction, and said first direction is substantiallyperpendicular to said second direction.
 9. The process of claim 8,wherein: said at least one inboard slit is oriented in a width-wisedirection, and said linear coin swath is oriented in a length-wisedirection.
 10. A process of manufacturing a core metal insert, includingthe steps of: forming at least one column of inboard slits in a metalblank so as to create a slitted metal blank, each inboard slit of saidat least one column of inboard slits extending continuously from arespective left lateral slit end to a respective right lateral slit end;and forming a linear coin swath in said slitted metal blank whichtraverses each inboard slit of said at least one linearly aligned columnof inboard slits so that said slitted metal blank is expanded to createa plurality of inboard gaps defined therein which are aligned in acolumn, wherein said linear coin swath is spaced apart from both saidrespective left lateral slit end and said respective right lateral slitend of each inboard slit of said at least one linearly aligned column ofinboard slits during said linear coin swath forming step, and whereinsaid linear coin swath forming step includes the step of displacing aquantity of metal of said slitted metal blank so as to create acoin-formed bridge with said quantity of metal which (i) is positionedwithin each of said plurality of inboard gaps, and (ii) divides eachinboard gap of said plurality of inboard gaps into a first inboardsubgap and a second inboard subgap.
 11. The process of claim 10, whereineach of said first inboard subgap and said second inboard subgap extendsthrough said core metal insert.
 12. The process of claim 10, wherein:each of said plurality of inboard gaps is defined by a leading legportion and a trailing leg portion of said core metal insert whichcollectively define an entire outer boundary of said respective inboardgap, said coin-formed bridge includes (i) a leading bridge portion whichextends into said respective inboard gap from said leading leg portion,and (ii) a trailing bridge portion which extends into said inboard gapfrom said trailing leg portion, and said leading bridge portion contactssaid trailing bridge portion so that said bridge continuously extendsfrom said leading leg portion to said trailing leg portion.
 13. Aprocess of manufacturing a core metal insert, including the steps of:cutting a plurality of inboard slits in a metal blank so as to create aslitted metal blank, each of said plurality of inboard slits extendingcontinuously from a respective left lateral slit end to a respectiveright lateral slit end; and coining said slitted metal blank so thatsaid core metal insert is manufactured with (i) a plurality of inboardgaps defined therein which are aligned in a column, and (ii) acoin-formed bridge which is positioned within each inboard gap of saidplurality of inboard gaps and which divides each inboard gap of saidplurality of inboard gaps into a first inboard subgap and a secondinboard subgap, each of said first inboard subgap and said secondinboard subgap extends through said core metal insert, wherein saidcutting step includes the step of forming at least one linearly alignedcolumn of inboard slits, wherein said coining step includes the step offorming a linear coin swath which traverses each inboard slit of said atleast one linearly aligned column of inboard slits, and wherein saidlinear coin swath is spaced apart from both said respective left lateralslit end and said respective right lateral slit end of each inboard slitof said at least one linearly aligned column of inboard slits duringsaid linear coin swath forming step.
 14. The process of claim 13,wherein each inboard gap of said plurality of inboard gaps is defined bya leading leg portion and a trailing leg portion of said core metalinsert which collectively define an entire outer boundary of said eachinboard gap.
 15. The process of claim 14, wherein said coin-formedbridge includes (i) a leading bridge portion which extends into saidinboard gap from said leading leg portion, and (ii) a trailing bridgeportion which extends into said inboard gap from said trailing legportion.
 16. The process of claim 15, wherein said leading bridgeportion contacts said trailing bridge portion so that said coin-formedbridge continuously extends from said leading leg portion to saidtrailing leg portion.
 17. The process of claim 13, wherein said linearcoin swath is oriented relative to said plurality of inboard gaps suchthat, when said core metal insert is viewed in a plan view, said linearcoin swath forms an intersection with each inboard gap of said pluralityof inboard gaps which are aligned in said column.
 18. The process ofclaim 13, wherein: each of said plurality of inboard slits is orientedin a first direction, said linear coin swath is oriented in a seconddirection, and said first direction is substantially perpendicular tosaid second direction.
 19. The process of claim 18, wherein: each ofsaid plurality of inboard slits is oriented in a width-wise direction,and said linear coin swath is oriented in a length-wise direction.